Caterpillar Cat 438D BACKHOE LOADER (Prefix BPE) Service Repair Manual Instant Download (BPE00001)

1
Service Repair Manual
Model 438D BACKHOE LOADER
2
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Product BACKHOE LOADER Model 438D BACKHOE
LOADER BPE Configuration 438D Backhoe Loader
BPE00001-00663 (MACHINE) POWERED BY 3054
Engine Disassembly and Assembly 416D, 420D,
424D, 428D, 430D, 432D, 438D and 442D Backhoe
Loaders Power Train Media Number
-RENR3578-12 Publication Date -01/04/2010 Date
Updated -13/04/2010
i01381641
Transmission (Direct Drive) - Assemble SMCS -
3030-016-DD 3066-016 Assembly Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 137-8102 Spring Compressor 1
B 1P-1859 Snap Ring Pliers 1
C 4C-3652 Spring Compressor 1
D 6V-2157 Link Bracket 1
E 8T-5096 Indicator 1
F 1U-5750 Engine Stand 1
Note The transmission will be assembled in major
components. The major components will then be
assembled. Note Cleanliness is an important
factor. Before assembly, all parts should be
thoroughly cleaned in cleaning fluid. Allow the
parts to air dry. Wiping cloths or rags should
not be used to dry parts. Lint may be deposited
on the parts which may cause later trouble.
Inspect all parts. If any parts are worn or
damaged, use new parts for replacement. Note
Apply a light film of clean transmission oil to
all components before assembly.
Transmission case
3
Illustration 1 g00729262 Note Install the shims
behind each bearing cup that was recorded on the
disassembly procedure. 1. Install bearing cups
(60), (61), (62), (63), and (64) .
(Direct Drive) Input Shaft
Illustration 2 g00731364 1. Install the needle
thrust bearings on the shafts. The open end of
cups (1) must point away from the bearings or
gears that are contacted.
4
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Illustration 3
g00729745
2. Install the seals on piston (56) .
Illustration 4 g00729752 3. Install piston (56).
Install the retainer and spring (55). Use tooling
(A) and a suitable press in order to compress
spring (55). Use tooling (B) in order to install
snap ring (54) .
Illustration 5
g00729210
6

1. Install clutch pack (53) and retainer (52) .
2. Repeat Steps 2 through 4 for the opposite end of
   the input shaft.

Illustration 6 g00729208 6. Install gear (51),
needle bearing (50), and spacer (49). Use tooling
(B) in order to install snap ring (48) .

• Illustration 7 g00729771
• Heat bearing cone (57) to 135 C (275 F).
  Install bearing cone (57) .
• Install the input shaft.

(Direct Drive) Reverse Shaft
7

• Illustration 8 g00729785
• Heat bearing cones (45) and (46) to 135 C (275
  F). Install bearing cones (45) and (46) .
• Install the reverse shaft.

(Direct Drive) Shaft

• Illustration 9 g00729792
• Heat bearing cones (45) and (46) to 135 C (275
  F). Install bearing cones (45) and (46) .
• Install the shaft.

(Direct Drive) Output Shaft (Rear)
8
Illustration 10
g00729806
1. Install gear (42) .
Illustration 11 g00729200 2. Install housing
(41) and gear (40). Use tooling (B) in order to
install snap ring (39) .
Illustration 12
g00729810
9
3. Install synchronizer (38). Install gear (37).
Heat bearing cone (36) to 135 C (275 F).
Install bearing cone (36) .
Illustration 13 g00729198 4. Install
synchronizer (35), spacer (34), and bearings (33)
.

• Illustration 14 g00729812
• Install gear (31) and (32). Heat bearing cone
  (30) to 135 C (275 F). Install bearing cone
• (30) .
• Install the output shaft (rear) in the
  transmission.

10
Illustration 15
g00729196
Illustration 16 g00729064 7. Install two
gearshift rods (23) on shift forks (29). Install
the gearshift rods in the transmission. Install
three balls (28), two springs (27), and O-ring
(26). Install plug (25) .
Illustration 17 g00729062 8. Install screws (24)
on each of the gearshift rods (23) .
11
(Direct Drive) Output Shaft (Front)
Illustration 18
g00729861
1. Install seals on piston (22) .
Illustration 19
g00729879
12

• Illustration 20 g00730110
• Install piston (22), spring (19), and retainer
  (21) .
• Use tooling (C) and a suitable press in order to
  compress spring (19). Use tooling (B) in order to
  install snap ring (20) .

Illustration 21
g00728948
4. Install clutch pack (18) and retainer (17) .
Illustration 22 g00728945 5. Install thrust
washer (16), needle bearing (15), spacer (14),
and two roller bearings (13) .
13
Illustration 23 g00729892 6. Heat bearing cone
(11) to 135 C (275 F). Install bearing cone
(11) .
Illustration 24 g00729903 7. Heat bearing cone
(10) to 135 C (275 F). Install bearing cone
(10) .
Illustration 25
g00728940
8. Install front output shaft (9) .
14
Final Assembly
Illustration 26 g00730114 Note Clean the mating
surfaces of case (7). Apply a continuous bead of
1U-8846 Sealant to the mating surface of the
case. 1. Attach tooling (D) to case (7). Attach a
suitable lifting device to tooling (D). Use
fourteen bolts (8) in order to install case (7).
The weight of case (7) is 42 kg (94 lb).
Illustration 27 g00730079 2. Install a bolt in
the output shaft. The output shaft must be fully
seated. Install tooling (E), as shown. Zero
tooling (E). Pry up on the bolt and record the
reading on tooling (E). The reading must be 0.03
mm (0.0012 inch) to 0.08 mm (0.0031 inch). Add or
remove shims in Step 1 in the Case Assembly
Procedure in order to obtain the correct reading.
15
Illustration 28 g00730086 3. Repeat Step 1 for
the input shaft and the output shaft (front). Use
the same tolerance for all of the shafts. Remove
the expansion plug in order to check the input
shaft. Use a screwdriver to pry up on the input
shaft. Install a new 1H-9721 Expansion Plug .
Illustration 29
g00728906
4. Install yoke (4), washer (5), and bolt (6) .
Illustration 30
g00728902
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5. Install plug (3) .
Illustration 31 g00728895 6. Install Implement
pump drive shaft (2) in transmission (1) .
Illustration 32 g00730116 7. Remove transmission
(1) from tooling (F) . End By Install the
transmission. Refer to Disassembly and Assembly,
"Transmission (Direct Drive) - Install".
Copyright 1993 - 2019 Caterpillar Inc. All Rights
Reserved. Private Network For SIS Licensees.
Thu Oct 3 123010 UTC0800 2019
17
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Previous Screen
Product BACKHOE LOADER Model 438D BACKHOE
LOADER BPE Configuration 438D Backhoe Loader
BPE00001-00663 (MACHINE) POWERED BY 3054
Engine Disassembly and Assembly 416D, 420D,
424D, 428D, 430D, 432D, 438D and 442D Backhoe
Loaders Power Train Media Number
-RENR3578-12 Publication Date -01/04/2010 Date
Updated -13/04/2010
i01459029
Transmission (Direct Drive) - Install SMCS -
3030-012-DD Installation Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 8S-7640 Stand 2
A 8S-7611 Tube 2
A 8S-7615 Pin 2
B 1U-9760 Jack Stand 2
C 1U-7505 Transmisson Jack 1
D 1U-7558 Mounting Brackets 2
E FT-2535 Engine Support Bar Assembly 1
18
Illustration 1 g00762601 1. Attach tooling (D)
to tooling (C) and transmission (10) in order to
maintain a good balance.
Illustration 2 g00762359 2. Use tooling (C) in
order to position transmission (10). The weight
of transmission (10) is 185 kg (408 lb).
Illustration 3
g00762479
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3. Install fourteen bolts (11) .
Illustration 4 g00762562 4. Slide rod assembly
(9) on the transmission lever and tighten bolt
(8) .
Illustration 5
g00762561
5. Connect three electrical connectors (7) .
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Illustration 6
g00762358

1. Install four bolts (5) .
2. Repeat Step 6 for the opposite side.
3. Install two bolts (6) .

Illustration 7
g00762357
9. Install plug (4) .
Illustration 8 g00762355 10. Remove tooling (E).
Install inspection plate (3) .
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Illustration 9
g00760890
11. Remove tooling (B) from front axle (2) .
Illustration 10
g00760888

• Remove tooling (A) from rear frame (1) .
• Fill the transmission with oil. Refer to
  Operation and Maintenance, SEBU7398, "Capacities"
  for the proper type and capacity of oil.
• ,
• End By
• Install the piston pump. Refer to Disassembly and
  AssemblyRENR3585, "Piston Pump (Implement and
  Steering) - Install".
• Install the rear drive shaft. Refer to
  Disassembly and Assembly, "Drive Shaft (Rear) -
• Remove and Install".
• Install the front drive shaft. Refer to
  Disassembly and Assembly, "Drive Shaft (Front) -
  Remove and Install".

Copyright 1993 - 2019 Caterpillar Inc. All Rights
Reserved. Private Network For SIS Licensees.
Thu Oct 3 123106 UTC0800 2019
22
Shutdown SIS
Previous Screen
Product BACKHOE LOADER Model 438D BACKHOE
LOADER BPE Configuration 438D Backhoe Loader
BPE00001-00663 (MACHINE) POWERED BY 3054
Engine Disassembly and Assembly 416D, 420D,
424D, 428D, 430D, 432D, 438D and 442D Backhoe
Loaders Power Train Media Number
-RENR3578-12 Publication Date -01/04/2010 Date
Updated -13/04/2010
i05395070
Transmission (Power Shift) - Remove SMCS -
3030-011-PM Removal Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 8S-7640 Stand 2
A 8S-7611 Tube 2
A 8S-7615 Pin 2
B 1U-9760 Jack Stand 2
C 1U-7505 Transmisson Jack 1
D 1U-7558 Mounting Brackets 2
E FT-2535 Engine Support Bar Assembly 1

• Start By
• Remove the front drive shaft. Refer to
  Disassembly and Assembly, "Drive Shaft (Front) -
  Remove and Install".
• Remove the rear drive shaft. Refer to Disassembly
  and Assembly, "Drive Shaft (Rear) - Remove and
  Install".
• Remove the piston pump. Refer to Disassembly and
  Assembly, RENR3585, "Piston Pump (Implement and
  Steering) - Remove".
• 1. Use a suitable lifting device in order to
  raise the machine to a height of 91.4 mm (36
  inch) between the ground and the side step.

23
Illustration 1
g00760888
2. Place tooling (A) under rear frame (1) .
Illustration 2
g00760890
3. Place tooling (B) under front axle (2) .
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Illustration 3 g03410213 4. Remove the
inspection cover. Install Tooling (E) in order to
support the engine when the transmission is
removed.
Illustration 4 g00760891 5. Disconnect seven
electrical connectors (3) . Cut three straps (4) .
Illustration 5 g00760892 6. Cut the strap and
disconnect three electrical connectors (5) .
26
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friend! Thank you very much for reading. Enter
the link into your browser. The full manual is
available for immediate download. https//www.ebo
oklibonline.com